Helmet liner

ABSTRACT

An adjustable liner for use with a protective helmet includes at least one bladder containing open cell foam within the bladder. The bladder is formed by a film that surrounds the foam. The film includes a port that regulates air transfer within the bladder of the liner. When a person dons the helmet having the liner for the first time, the liner&#39;s air port is open. When a wearer puts the helmet on his or her head, the foam compresses, thus causing air to escape from within the foam and bladder through the port. The port may then be closed so that air cannot re-enter the bladder or foam, and the foam is retained in its compressed form. When a new wearer wishes to don the same helmet, he or she may release the port to return the foam and bladder to its fully expanded form for a subsequent use.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.62/595,994, filed Dec. 7, 2017, which is hereby incorporated byreference in its entirety.

FIELD OF THE INVENTION

The present invention relates to a liner for use with a protectivehelmet. More particularly, the present invention relates to anadjustable liner that can be adjusted to accommodate various head shapesand sizes.

BACKGROUND OF THE INVENTION

Protective helmets are worn by participants in a variety of activitiesand sports, including but not limited to, baseball, softball, football,lacrosse, cycling, and hockey in order to help guard the wearer's headfrom trauma. However, such helmets are usually mass produced, and theytherefore cannot comfortably and safely fit the head of every possiblewearer, or even a majority of possible wearers. This can result indiscomfort or injury.

Some helmet manufacturers attempt to solve this problem by designinghelmets that have liners inside the helmet that aim to conform to thewearer's head. Such liners are made of a variety of materials, includingthick open cell foam. Other manufacturers utilize dial fit systems thatadjust chin straps to make the helmet fit more snugly to the user'shead. Another available system is a manual inflatable liner within ahelmet's interior that can be adjusted using a pump. Such inflatableliners start uninflated and then are inflated to conform to a head shapeusing a pump.

Other manufacturers utilize solutions that are adjusted a first time tofit a wearer's head, but then are permanently tailored to fit thatparticular wearer's head. In sports like baseball or softball, wheremultiple batters wear the same helmet, this is an undesirable solutionbecause the helmet cannot be used by multiple batters. Thus, theaforementioned liners and systems are often expensive, difficult andinconvenient to use, and/or lacking in actual performance.

SUMMARY OF THE INVENTION

An adjustable liner of the present invention for use within a helmetpreferably includes at least one bladder containing low density, opencell foam securely and snugly contained within the bladder. The bladderis preferably formed by a film that surrounds the foam.

The film may be a thermoplastic polyurethane (TPU), polyvinyl chloride(PVC), or similar material. Preferably, the film includes an inflationport that regulates the transfer of air within the bladder of the liner.

In use, when a player dons the helmet having the liner for the firsttime, the liner's air port is open. This allows the bladder and foam tobe full of air, and thus both are preferably in a fully expandedposition. When a wearer puts the helmet on his or her head, the foamcompresses to conform to the wearer's head, as does the bladder. Airpreferably escapes from within the foam and bladder through the port.The port may then be closed so that air cannot reenter the bladder orfoam. The foam is therefore retained in its compressed form. Withsubsequent wears by the same wearer, the above described fitting processneed not be repeated.

However, when a new wearer wishes to don the same helmet (or when awearer wishes to refit the helmet), he or she should first release theport to return the foam and bladder to its fully expanded form. Then heor she may repeat the above described process to get the liner toconform to his or her head.

Depending on the sport in which the activity is used, the liner may takeon a number of sizes and shapes. Similarly, nearly any number of linersmay be used within a helmet's interior to properly conform to a wearer'shead.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the various embodiments of the presentinvention, reference may be made to the accompanying drawings in which:

FIG. 1 is a front elevation view of a helmet liner constructed accordingto the teachings of the present invention;

FIG. 2 is an enlarged view of a port of the helmet liner of FIG. 1; and

FIG. 3 is a plan view of the helmet liner of FIG. 1.

While the disclosure is susceptible to various modifications andalternative forms, specific embodiments thereof are shown by way ofexample in the drawing and will herein be described in detail. It shouldbe understood, however, that the drawings and detailed descriptionpresented herein are not intended to limit the disclosure to theparticular embodiment disclosed, but on the contrary, the intention isto cover all modifications, equivalents, and alternatives falling withinthe spirit and scope of the present disclosure.

DETAILED DESCRIPTION OF THE DRAWINGS

The invention will now be described with reference to the drawingfigures, in which like reference numerals refer to like partsthroughout. For purposes of clarity in illustrating the characteristicsof the present invention, proportional relationships of the elementshave not necessarily been maintained in the drawing figures.

Turning first to FIG. 1, a reusable helmet liner 1 is illustrated foruse within a protective helmet (not illustrated) used in sportsincluding, but not limited to, baseball, softball, football, lacrosse,cycling, and hockey. The helmet liner 1 is sized and shaped for use nearthe rear bottom of a protective helmet. It will be understood that thehelmet liner 1 may take on a nearly limitless number of positions,sizes, and shapes to better protect the forehead, ears, crown of thehead, lower skull, etc. It should be noted that more than one helmetliner such as the helmet liner 1 may be included within a helmet'sinterior to help make sure the above and other areas of the head areadequately protected.

As shown in FIG. 1, the helmet liner 1 preferably includes a film 5 thatforms one or more than one bladder member 10. At least one section oflow density foam 15, or other compressible material, is contained withinan interior cavity of each bladder member 10 of the helmet liner 1. Thefoam 15 should be able to expand and contract when air enters or leavestherefrom. As such, the foam 15 is preferably made of open cell foam.Other foam materials are also envisioned that are expandable andcontractable when air is introduced to the foam or removed from thefoam. In yet another alternative embodiment, the compressible materialmay simply be air contained within a bladder member such as the bladdermember 10.

The film 5 may be made of a variety of pliable, easily washablematerials, but in preferred embodiments, is made of thermoplasticpolyurethane (TPU) or polyvinyl chloride (PVC). The film 5 preferably issealed at its edges and on all its surfaces to form the interior cavityof the bladder member 10, with the exception of a port 20, which isdescribed in greater detail herein below.

The interior cavity of each bladder member 10 may therefore beconsidered as an air pocket within the film 5. In the preferredembodiment, the shape of each bladder member 10 is substantially similarto the low density foam 15 housed therein, and only slightly larger thansuch low density foam 15. When the low density foam 15 is within thebladder member 10, it is securely contained therein. In otherembodiments where the liner 1 is used in a different helmet region, thebladder member 10 and the foam 15 may take on a number of differentsizes and shapes.

In the embodiment illustrated in FIG. 1, which is the embodiment of thehelmet liner 1 when it is being fitted to a user's head, the air port 20is preferably in its open position. In the open position, as understoodin the art, the air port 20 preferably allows for passive fluidcommunication between the interior of the bladder member(s) 10 andatmospheric air surrounding the liner 1. The bladder member(s) 10 neednot be inflated to be in its expanded, non-compressed state. Air mayalso escape from the bladder member(s) 10 when pressure is applied tothe low density foam 15, when the air port 20 is in the open position.In its closed position, the air port 20 preferably prevents air fromescaping or entering the bladder member(s) 10. Because the air port 20may passively allow air to enter the bladder member 10 until it isclosed, the air port 20 may be described as an air bypass port.

In the embodiment of the helmet liner 1 shown in FIG. 1, three differentpieces of foam 15 are provided, one in each of three respective bladdermembers 10. Small bladder member channels 22 are provided betweenadjacent bladder members 10 formed from film 5. Two bladder memberchannels 22 are shown in FIG. 1, with one respective bladder memberchannel 22 between each of the three bladder members 10. The bladdermember channels 22 allow for fluid communication between the bladdermembers 10. When the air port 20 is open, air may be removed from anyand all of the bladder members 10. Inflation of the bladder members 10may also occur via the air port 20 and bladder member channels 22, asdescribed herein below.

The air port 20 is shown in greater detail in FIG. 2. As can beappreciated by those skilled in the art, a knob 25 may be provided onthe air port 20. The knob 25 may be usable to switch the air port 20between its open position and closed positions. In the illustratedembodiment, turning the knob 25 counterclockwise opens the port 20, andturning the knob 25 clockwise closes the port 20. In alternativeembodiments, turning the knob 25 clockwise may open the port 20, andturning the knob 25 counterclockwise may close the port 20.Alternatively, a different known or foreseeable mechanism altogether maybe used to open and close the port 20.

With the port 20 in its open position, the fitting process for a wearermay begin. The protective liner 1 is positioned within the interior of aprotective helmet. In a preferred embodiment, the air port 20 faces awayfrom the wearer's head when in use, to avoid damage the wearer's head inthe case of a collision. When the helmet is then placed on the wearer'shead with the port 20 in its open position, the low density foam 15preferably compresses to conform to the shape of the wearer's head. Asthe foam 15 compresses, the air bladder member(s) 10 also preferablycompresses, forcing air out from the port 20.

When the helmet securely fits, a wearer may close the port 20,preferably by turning the knob 25 in a clockwise direction. By closingthe port 20, no further air escapes from the bladder member(s) 10. Thefilm 5 is therefore positioned snugly against the low density foam 15 inthe shape of the wearer's head. With the port 20 closed, the low densityfoam 15 and bladder member(s) 10 preferably retain their contouredshape, because air cannot reenter the bladder(s) 10 or foam 5 to permitre-inflation. FIG. 3 illustrates an example of a compressed form of thehelmet liner 1. Thus, the wearer preferably need not perform this“fitting” method every time he or she dons the helmet, and the helmetretains a custom fit for that wearer so long as the air port 20 is notreopened.

However, in the event that a different wearer wishes to wear the helmet,or if the wearer would like to refit the helmet to his or her head, thehelmet liner 1 (or helmet liners 1 if multiple liners are containedwithin the helmet) may be refit. To do so, the knob 25 or othermechanism may be adjusted to turn the port 20 to the open position. Airwould then be able to reenter the bladder(s) 10, thus allowing the foamto return to its original, expanded position. The above describedfitting process may be repeated, and the liner 1 may be again reshaped.

From the foregoing, it will be seen that the various embodiments of thepresent invention are well adapted to attain all the objectives andadvantages hereinabove set forth together with still other advantageswhich are obvious and which are inherent to the present structures. Itwill be understood that certain features and sub-combinations of thepresent embodiments are of utility and may be employed without referenceto other features and sub-combinations. Since many possible embodimentsof the present invention may be made without departing from the spiritand scope of the present invention, it is also to be understood that alldisclosures herein set forth or illustrated in the accompanying drawingsare to be interpreted as illustrative only and not limiting. The variousconstructions described above and illustrated in the drawings arepresented by way of example only and are not intended to limit theconcepts, principles and scope of the present invention.

Many changes, modifications, variations and other uses and applicationsof the present invention will, however, become apparent to those skilledin the art after considering the specification and the accompanyingdrawings. All such changes, modifications, variations and other uses andapplications which do not depart from the spirit and scope of theinvention are deemed to be covered by the invention which is limitedonly by the claims which follow.

What is claimed is:
 1. A helmet liner for use within a protectivehelmet, the helmet liner comprising: a bladder member formed by aprotective film, the bladder member having at least one interior cavity;an open cell foam contained within the at least one interior cavity ofthe bladder member; and an air port positioned on the protective film,the air port selectively allowing for fluid communication betweenatmosphere and the at least one interior cavity of the bladder member.2. The helmet liner of claim 1, wherein the film is made of at least oneof TPU and PVC.
 3. The helmet liner of claim 1, wherein air passivelyenters the air port when it is in the open position until the bladdermember is full.
 4. The helmet liner of claim 1, wherein when the airport is closed, air does not enter or escape the bladder member.
 5. Thehelmet liner of claim 1, wherein the air port is an air bypass port. 6.The helmet liner of claim 1, wherein the helmet liner is selectivelyattached to an interior portion of the protective helmet.
 7. The helmetliner of claim 1, wherein the helmet liner includes a plurality ofbladders.
 8. The helmet liner of claim 7, wherein the plurality ofbladders are in fluid communication with one another via a plurality ofchannels.
 9. A helmet liner for use within a protective helmet, thehelmet liner comprising: a bladder member formed by a protective film; acompressible material contained within the protective film; and an airbypass port positioned on the protective film, the air bypass port influid communication with the bladder member.
 10. The helmet liner ofclaim 9, wherein the film is made of at least one of TPU and PVC. 11.The helmet liner of claim 9, wherein air passively enters the air portwhen it is in the open position until the bladder member is full. 12.The helmet liner of claim 9, wherein when the air port is closed, airdoes not enter or escape the bladder member.
 13. The helmet liner ofclaim 9, wherein the compressible material is open cell foam.
 14. Thehelmet liner of claim 9, wherein the helmet liner is selectivelyattached to an interior portion of the protective helmet.
 15. The helmetliner of claim 9, wherein the helmet liner includes a plurality ofbladders.
 16. The helmet liner of claim 15, wherein the plurality ofbladders are in fluid communication with one another via a plurality ofchannels.
 17. A method of fitting a protective helmet to a wearer'shead, the method comprising the steps of: donning the helmet so that ahelmet liner comprising a bladder member formed by a protective film andfilled with low density foam abuts a portion of the wearer's head;compressing the low density foam by the wearer's head applying a forceto the helmet liner; and closing an air port located on the protectivefilm when the helmet liner fits the wearer's head.
 18. The method ofclaim 17, further comprising the step of opening the air port when theprotective helmet is to be re-used so that the helmet liner returns toits shape and size prior to donning.